Method of forming an automotive valve cover with integral positive crankcase ventilation
First Claim
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1. A method of forming an integrated PCV with a plastic valve cover, the method comprising:
- a) providing a polymeric material; and
b) molding the polymeric material to form a single substantially continuous body portion for the valve cover wherein the valve cover includes;
i) a plurality of walls defining at least one internal cavity;
ii) a tubular structure defining a tunnel, the tubular structure including a through-hole at one end wherein the tubular structure is adapted for positive crankcase ventilation; and
iii) at least one mating surface;
c) adhesively securing the valve cover to an engine head with an adhesive that includes epoxy wherein the adhesive is secured to the at least one mating surface of the cover and to a mating surface of the engine head and wherein the adhesive forms a joint with a tensile strength of at least about 6500 psi.
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Abstract
A method of forming a valve cover suitable for attachment to an engine head is disclosed. The valve cover is molded from a plastic material to include at least one structure of a positive crankcase ventilation (PCV) system. Additionally, the design of the valve cover includes various advantages including, for example, structural integrity, ease of installation or the like.
38 Citations
21 Claims
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1. A method of forming an integrated PCV with a plastic valve cover, the method comprising:
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a) providing a polymeric material; and
b) molding the polymeric material to form a single substantially continuous body portion for the valve cover wherein the valve cover includes;
i) a plurality of walls defining at least one internal cavity;
ii) a tubular structure defining a tunnel, the tubular structure including a through-hole at one end wherein the tubular structure is adapted for positive crankcase ventilation; and
iii) at least one mating surface;
c) adhesively securing the valve cover to an engine head with an adhesive that includes epoxy wherein the adhesive is secured to the at least one mating surface of the cover and to a mating surface of the engine head and wherein the adhesive forms a joint with a tensile strength of at least about 6500 psi. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method of forming an integrated PCV with a plastic valve cover, the method comprising:
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a) providing filled thermoplastic material; and
b) blow molding the filled thermoplastic material to form a single substantially continuous body portion for the valve cover wherein the valve cover includes;
i) a central portion;
ii) a pair of transverse portions extending away from the central portion, the transverse portions assisting in defining at least one internal cavity that is substantially enclosed by the valve cover; and
iii) a tubular structure intermediate the transverse portions and defining a tunnel, the tubular structure including a through-hole at one end and a valve at an opposite end wherein the tubular structure is adapted for positive crankcase ventilation;
wherein the step of blow molding includes placement of a parison within a cavity of a first tool adapted for shaping the valve cover. - View Dependent Claims (11, 12, 13, 14, 15, 16)
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17. A method of forming an integrated PCV with a plastic valve cover, the method comprising:
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a) providing a polyamide blend material; and
b) blow molding the polyamide blend material to form a single substantially continuous body portion for the valve cover wherein the valve cover includes;
i) a central portion;
ii) a pair of transverse portions extending away from the central portion, the transverse portions assisting in defining at least one internal cavity that is substantially enclosed by the valve cover;
iii) a tubular structure intermediate the transverse portions and defining a tunnel, the tubular structure include a through-hole at one end and a valve at an opposite end wherein the tubular structure is adapted for positive crankcase ventilation; and
iv) at least one surface configured for matingly contacting at least one surface of an engine head; and
c) providing an insulating material in at least a portion of the at least one internal cavity of the valve cover; and
d) adhesively securing the at least one surface of the body portion to the at least one surface of the engine head with an epoxy adhesive;
wherein the step of blow molding includes placement of a parison within a cavity of a first tool adapted for shaping the valve cover. - View Dependent Claims (18, 19, 20, 21)
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Specification